Lopi Leyden Pellet Stove User Manual

Leyden

Pellet Stove

• Horizontal Or Vertical Vent

• Freestanding Stove

• Mobile Home Approved

• Class A Chimney Retrofit

• Hearth Stove into Existing Masonry Chimney , Masonry Fireplace, or Z.C. Fireplace

Tested and Listed by

Omni-Test Laboratories, Inc.

Beaverton, Oregon

Report # 028-S-77-2

ASTM E1509-2004

-- Please read this entire manual before installation and use of this pellet fuelburning room heater. Failure to follow these instructions could result in property

damage, bodily injury, or even death.

-- Contact local building or fire officials about restrictions and installation inspection requirements in your area.

-- Save these instructions.

Installer: After installation give this manual to the home-owner and explain operation of this stove.

$10.00	Copyright 2007, T.I.	Part # 100-01184

4061016	4800 Harbour Pointe Blvd. SW
	Mukilteo, WA 98275

2	Introduction

Introduction

Congratulations!

You have just purchased one of the finest hearth products on the market.

Lopi heating appliances are solidly crafted and uniquely designed for the American lifestyle and proudly built in the U.S.A.

Lopi wood, gas and pellet stoves, fireplaces and inserts have been America's Favorite Fire for over twentyfive years. Our reputation for solid craftsmanship, reliable performance and unbeatable heating efficiency has been a winning combination year after year, and the favorite fire of families across the nation.

Whichever Lopi product you've purchased, we're sure it will warm your home and brighten your day, for many years to come.

If you have any questions, concerns, or comments, please contact your local Lopi hearth design center. They are authorized, certified, and factory-trained hearth professionals and should always be consulted on the installation and operation of your Lopi hearth appliance for the best performance and highest satisfaction.

We also have one of the best warranties in the industry. It is our desire for you to be completely happy with your purchase.

For information on our many other Lopi products, visit your local Lopi Hearth Design center or log on to www.LopiFire.com.

For celebrations, gatherings or just everyday life, Lopi is America's Choice.

Enjoy!

Important Information

No other Leyden heater has the same serial number as yours. The serial number is on the safety label on the back of the appliance.

This serial number will be needed in case you require service of any type.

Model:

Leyden PS

Serial Number:

Purchase Date:

Purchased From:

Mail your Warranty Card Today, and Save Your Bill of S a l e .

To receive full warranty coverage, you will need to show evidence of the date you purchased your heater. Do not mail your Bill of Sale to us.

We suggest that you attach your Bill of Sale to this page so that you will have all the information you need in one place should the need for service or information occur.

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Table of Contents

3

Introduction
Introduction ......................................................	2
Important Information .........................................	2
Safety Precautions
Safety Precautions ............................................	4
Specifications
Heating Specifications ........................................	6
Dimensions.......................................................	6
Electrical Specifications......................................	6
Fuel.................................................................	6
EPA Compliance ................................................	6
Installation
Before You Begin ...............................................	7
Packing List......................................................	7
Installation Options............................................	7
Planning The Installation .....................................	7
Stove Placement ...............................................	7
Floor Protection Requirements..............................	7
Clearances - Straight Installation ..........................	8
Clearances - Corner Installation............................	8
Venting the Pellet Stove ......................................	9
Maximum Venting Distance .............................	9
Pellet Vent Type............................................	10
Installing the Pellet Vent.................................	10
Pellet Vent Termination...................................	10
Mobile Home Requirements ..................................	11
Outside Air (used for combustion) .........................	11
Alcove Installation Requirements ..........................	12
Baffle Installation...............................................	12
Door Seal Verification .........................................	12
Restrictor Adjustment .........................................	12
Thermostat Installation .......................................	13
Installation Example: Direct "Through-the-wall"
Installation .......................................................	14
Installation Example: Interior Vertical Installation ....	15
Installation Example: Class A Chimney Retrofit ........	16
InstallationExample:MasonryFireplaceHearthStove.......................	17
InstallationExample:Zero-Clearance(Metal)FireplaceHearthStove..18
InstallationExample:FreestandingMasonryChimney................	19
Operation
Safety Notice ....................................................	20
Location of Controls ...........................................	20
Starting the Heater for the First Time......................	20
Loading Pellets..................................................	21
The Two Modes of Operation ................................	21

Operation (continued)
Manual Mode.....................................................		22
Auto Mode ........................................................		23
Restrictor Adjustment .........................................		24
Adjusting the Fan Speed......................................		24
Start-Up Sequence.............................................		25
"MANUAL AUGER" Button....................................		25
"AUGER ON" Light..............................................		25
"FAULT" Light ....................................................		25
Fault Codes (for qualified service personnel only) .....		25
Power Outages..................................................		25
Using a Pellet/Corn Mix with This Heater .................		26
Maintenance
Daily Maintenance (whenever using the stove).........		27
Inspect the Burn ...........................................		27
Make Sure Pellets are Not Piling Up...................		27
Check Firepot for Clinkers ...............................		28
Cleaning the Firepot.......................................		28
Door Opening ...............................................		29
Bi-Weekly Maintenance (or every 10 bags of pellets).30
Flyash Removal ............................................		30
Clean the Hopper...........................................		30
Clean the Heat Exchange Tubes.......................		30
Clean the Baffles...........................................		31
Sweep Ash Into Ashpan..................................		32
Check Ashpan, Dispose if necessary................		33
Clean the Glass ............................................		33
Yearly Maintenance (or every two tons)..................		34
Clean the Vertical Exhaust Duct.......................		34
Clean the Exhaust Blower ...............................		36
Clean the Convection Blower ...........................		37
Clean the Vent ..............................................		37
Adjusting the Door Hinge and Latch...................		37
Check for Air Leaks Around the Door, Glass, and
Ashpan .......................................................		37
Replacement Parts ........................................		38
Normal	Operating Sounds
Normal Operating Sounds....................................		39
Safety	Label
Safety Label .....................................................		40
Warranty
Warranty ..........................................................		41
Index
Index...............................................................		42

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4

Gas

Safety Precautions

•Do not operate the heater if you smell smoke coming from the heater. Turn the MODE switch to "OFF", monitor your heater, and call your dealer .

•Never use gasoline, gasoline-type lantern fuel, kerosene, charcoal lighter fluid, or similar liquids to

start or 'freshen up' a fire in this heater. Keep all such liquids well away from the heater while it is in use.

•Do not unplug the heater if you suspect a malfunction. Turn the MODE SWITCH to "OFF" and periodically inspect the heater.

•Never try to repair or replace any part of the heater unless instructions are given in this manual. All other work should be done by a trained technician.

•The viewing door and ashpan must be closed and latched during operation.

•Never block free airflow through the open vents of the unit

•Do not operate the heater if the flame becomes dark & sooty of if the firepot overfills with pellets. Turn the MODE SWITCH to "OFF" and periodically inspect the heater (see "Running Your Heater").

Ok

Sealant

•Contact your local building officials to obtain a permit and information on any installation restrictions or inspection requirements in your area. Notify your insurance company of this heater as well.

•The exhaust system must be completely airtight and properly installed. The pellet vent joints must be sealed with RTV 500o F. (260o C.) silicone sealant.

•This unit must be properly installed to prevent the possibility of a house fire. The instructions must be strictly adhered to. Do not use makeshift methods or compromise in the installation.

•Your heater requires periodic maintenance and cleaning (see "Maintaining Your Heater"). Failure to maintain your heater may lead to smoke spillage in your home.

•Allow the heater to cool before carrying out any maintenance or cleaning. Ashes must be disposed in a metal container with a tight lid and placed on a non-combustible surface well away from the home or structure.

•This heater is designed and approved for pelletized wood fuel or a mixture up to 50% corn, 50% pellets. See page 26 for details on using a corn pellet mix.

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Safety Precautions

5

•The heater will not operate during a power outage. If

a power outage does occur, check the heater for smoke spillage and open a window if any smoke spills into the room.

•	Keep foreign objects out
?	of the hopper.

Mobile

Home

•Disconnect the power cord before performing any maintenance.

N O T E :

Turning the Mode Switch to "OFF" does not disconnect all power to the heater.

• Do not throw this manual away. This manual has important operating and maintenance instructions that you will need at a later time. Always follow the instructions in this manual.

• Do not place clothing or other flammable items on or near the heater. Because this heater can be controlled by a thermostat there is a possibility of the heater turning on and igniting any items placed on or near it.

•This heater must be connected to a standard 115 V., 60 Hz grounded electrical outlet. Do not use an adapter plug or sever the grounding plug. Do not route the electrical cord underneath, in front of, or over the heater.

•When installed in a mobile home, the heater must be bolted to the floor, have outside air, and NOT BE

INSTALLED IN THE BEDROOM (Per H.U.D. requirements). Check with local building officials.

•The exhaust system should be checked twice a year minimum for any build-up of soot or creosote.

•Do not touch the hot surfaces of the heater. Educate all children of the danger of a hightemperature heater. Young children should be supervised when they are in the same room as the heater.

•Travis Industries, Inc. grants no warranty, implied or stated, for the installation or maintenance of your heater, and assumes no responsibility of any consequential damage(s).

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6	Specifications

Heating Specifications

Approximate Maximum Heating Capacity (in square feet)* ........................................	800 to 2,250 Sq. Feet
Burn Rate (Pounds per Hour)**............................................................................	1.7 to 5.5
Maximum Burn Time on Low Burn** ......................................................................	29 Hours
Hopper Capacity ..............................................................................................	50 Pounds

*Heating capacity will vary depending on the home's floor plan, degree of insulation, and the outside temperature. It is alsoaffected by the fuel size, quality, and moisture level.

**Small pellets will increase or decrease the stated burn rates and burn times. Differences of plus or minus 20% depending on fuel quality may occur.

Dimensions

25"

27-3/4"

Weight: 390 Lbs.

27-1/4"

Center	Line
	7-3/4"

17-1/4"

4" Diameter

Exhaust

27"

NOTE:

Measure front and side clearances from the stove top. Rear and corner clearances are measured from the stove body.

Electrical Specifications

Electrical Rating.........................................................................................	115 Volts, 3.6 Amps, 60 Hz
Watts During Start-Up Sequence...................................................................	400 (approximately)
Watts During Operation ...............................................................................	180 (approximately)
Fuel

•This heater is designed and approved for pelletized wood fuel or a mixture up to 50% corn, 50% pellets. See page 26 for details on using a corn pellet mix.

EPA Compliance

This heater has been tested exempt from EPA Phase II Requirements by OMNI-Test Laboratories, Inc.

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7

Before You Begin

READ THIS ENTIRE MANUAL BEFORE YOU INSTALL AND USE THIS HEATER. FAILURE TO FOLLOW THE INSTRUCTIONS MAY RESULT IN PROPERTY DAMAGE, BODILY INJURY, OR EVEN DEATH.

Check with local building officials for any permits required for installation of this pellet heater and notify your insurance company before proceeding with installation.

Packing List

• Thermostat & Wire

• Scraper Rod Tool • Brush • Spare Fuse • Bottle Brush • Door Tool

• (2) Floor Mounting Brackets

Installation Options

•Residential or Mobile Home (see the section "Mobile Home Requirements")

•Alcove Compatible (see the section "Alcove Installation")

•Horizontal or Vertical Vent

•Outside Air Compatible

•Vent with L-Vent, L-Vent Fireplace Liner, or Type A Chimney (with adapter)

Planning The Installation

HINT:	Have an authorized Travis Industries dealer install this heater. If you install the heater
	yourself, have your dealer review your installation plans.
HINT:	Sketch out a detailed plan of the installation including dimensions. Then verify the
	dimensions with the requirements listed in this manual.
HINT:	When determining the location of the stove, locate the wall studs (for horizontal
	penetrations) and ceiling trusses (for vertical penetrations). You may wish to adjust the
	stove position slightly to ensure the vent does not intersect with a framing member.
HINT:	Place the heater outside and load 10 pounds of pellets inside the hopper. Plug the
	heater in and let it run on HIGH until the pellets run out. This will cure the paint and burn
	off any oil on the steel, eliminating any smell inside the home.

Stove Placement

•Stove must be placed so that no combustibles are within, or can swing within (e.g. drapes, doors), 36" of the front of the heater.

•If the stove is placed in a location where the ceiling height is less than 7', it must follow the requirements in the section "Alcove Installation Requirements".

HINT:	REDUCING CLEARANCES - Clearances may be reduced by methods specified in NFPA
	211, listed wall shields, pipe shields, or other means approved by local building or fire
	officials.

•Heater and floor protection must be installed on a level, secure floor.

Floor Protection Requirements

•The heater must be installed on a non-combustible floor protector extending the full width and depth of the heater and extending 6" in front (minimum 27-3/4" wide by 31" deep) (minimum .018" thick - 26 gauge) .

•Must extend under and 2" to each side and rear of a "Tee" (if used).

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8 Installation (For Qualified Installers Only)

Clearances - Straight Installation

Through the Wall Installations

Interior Vertical Vents

	3”
	Minimum		2”
3” Minimum		“Tee”	Minimum
7” Minimum		7” Minimum
Floor Protection
6” Minimum	6” Minimum
Clearances - Corner Installation

Through the Wall Vents

Interior Vertical Vents

3” Minimum

3” Minimum	2”
	Minimum
45° Elbow
	“Tee”
	3” Minimum
3” Minimum
	3”
	Minimum

6” Minimum

45°

6” Minimum

Note:	If interior vertical pellet vent is used, the clearance to the backwall is determined by the
	upward-turning elbow or "Tee". It will vary in depth depending on the brand of pellet vent
	used (it is approximately 5"). Before placing the heater, connect the elbow or "Tee" and
	measure off the 3" clearance.

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Venting the Pellet Stove

•PELLET VENT MUST MAINTAIN A MINIMUM 3" CLEARANCE TO ANY COMBUSTIBLE (INSTALL VENT AT CLEARANCES SPECIFIED BY THE VENT MANUFACTURER).

•DO NOT CONNECT THE PELLET VENT TO A VENT SERVING ANY OTHER APPLIANCE OR STOVE.

•DO NOT INSTALL A FLUE DAMPER IN THE EXHAUST VENTING SYSTEM OF THIS UNIT.

•USE AN APPROVED WALL THIMBLE WHEN PASSING THE VENT THROUGH WALLS AND A CEILING SUPPORT/FIRE STOP SPACER WHEN PASSING THE VENT THROUGH CEILINGS (MAKE SURE TO MAINTAIN 3" CLEARANCE TO ANY COMBUSTIBLES.

•No more than one tee and 180° of elbows (one tee with two 90° elbows, one tee with one 90° and two 45° elbows, etc.).

Maximum Venting

Distance

•Vent must have a support bracket every 5' of pellet vent when exterior of structure

The vent height and run must not exceed the distance shown in the shaded region shown to the right.

33 Feet

(max.)

30 Feet

25 Feet

20 Feet

Venting into this shaded area may require restrictor

adjustments. See the

15 Feet

section “Restrictor Adjustment” for details.

10 Feet

NOTE: To achieve optimum performance, we

recommend keeping the vent as short as possible

(horizontal run especially).	5 Feet

0 Feet

10Feet (max.)

0Feet

5Feet

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Pellet Vent Type

•Must be 4" diameter Type "L" (except for masonry fireplace installations) - or - connect the vent to a factory built type "A" chimney. All vent joints (including adapters, elbows, etc… ) must be sealed with 500° F. RTV silicone.

Installing the Pellet Vent

.RTV °F 500Silicone

Seal each vent section (including adapters, elbows, etc...) by injecting a liberal amount of 500° F. RTV silicone into the gap between sections.

•Horizontal sections must have a 1/4" rise every 12" of travel.

•Pellet vent connections must be sealed airtight with 500° F. RTV silicone and screwed together with at least three sheet metal screws.

Pellet Vent Termination

•Vent must terminate on the exterior of the dwelling. Horizontal terminations must protrude a minimum12" from the wall. Vertical terminations must protrude a minimum 24" from the roof surface. In addition, all clearances listed below must be met.

•Must have an approved cap (to prevent water from entering) or a 45° downturn with rodent screen.

•If the termination is located on a windy side of the house, an approved house shield is recommended to prevent soot from building up on the side of the house.

•Must not be located where it will become plugged by snow or other material.

H

X G

A

F

B

D

C

H F

A

E

NOTE: Measure clearances to the nearest edge of the exhaust hood.

AMinimum 4' clearance below or beside any door or window that opens Minimum 1’ clearance below or beside any window that does not open.

BMinimum 1' clearance above any door or window that opens

CMinimum 2' clearance from any adjacent building

DMinimum 7' clearance above any grade when adjacent to public walkways NOTE: Vent may not terminate in covered walkway or breezeway.

EMinimum 2' clearance above any grass, plants, or other combustible materials

FMinimum 3' clearance from any forced air intake of any other appliance

GMinimum 2' clearance below eaves or overhangs

HMinimum 1' clearance horizontally from combustible wall

X	Must be a minimum of 2' above the roof

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Mobile Home Requirements

•Outside air is required (used for combustion) - see the directions below.

•The heater must be bolted to the floor (Some states do not require this; check with your local building department). See the illustration to the right.

•The heater must be grounded to the steel chassis of the mobile home (Some states do not require this; check with your local building department).

WARNING: DO NOT INSTALL IN SLEEPING ROOM.

CAUTION: THE STRUCTURAL INTEGRITY OF THE MANUFACTURED HOME FLOOR, WALL, AND CEILING/ROOF MUST BE MAINTAINED.

The leveling bolts in the legs may be used in conjunction with the included clips (sku

210-03924) to secure the stove to the floor.

Outside Air (used for combustion)

•Must not be drawn from an enclosed space (garage, unventilated crawl space).

HINT:	Travis Industries strongly suggests outside air for all residential installations, especially for
	those that are energy efficient, air-tight homes.

•Must not be over 15' long (the kit includes a 4’ length – additional 3” diameter duct may be used).

•Must be made with 3" diameter or larger metal or aluminum duct with a metal screen attached to the end to keep out rodents (P.V.C. or other combustible materials may not be used). We recommend the Travis Industries Outside Air Kit (part # 99200136).

•Must not terminate above or within 1' of the chimney termination.

•Must have a rain cap or down-turned elbow to prevent water from entering.

•Must be located so that it will not become plugged by snow or other material.

A screen is required to prevent rodents from entering.

3” Diameter Air Duct

Air may be drawn from a ventilated crawl space.

Outside air entrance must be placed so it does not become blocked by snow.

Botttom of Stove

Use a hose clamp to secure the aluminum air duct to the air inlet flange on the stove.

Air Duct (3” Dia.)

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1 2 Installation (For Qualified Installers Only)

Alcove Installation Requirements

When the pellet stove is placed in a location where the ceiling height is less than 7' tall, it is considered an alcove installation. Because of the reduced height, the requirements listed below must be met.

•	Minimum height is 55"	•	Maximum depth is 48"
•	Minimum width is 41-1/4"	•	Minimum clearance of 7" on each side and 3" on back

Baffle Installation

Install the baffles included with the stove (see page 31 for details).

Door Seal Verification

The door is aligned prior to leaving the factory. However, shipping and installation may cause the door to become mis-aligned. Verify the door is correctly aligned and seals properly (see the section "Door Seal" under Yearly Maintenance).

Restrictor Adjustment

The restrictor “fine tunes” your appliance, ensuring it pulls the correct amount of air through the firebox. Altitude, vent configuration, and other factors make restrictor adjustment necessary for every installation.

NOTE: the optimal restrictor position will vary over time as soot builds up inside the exhaust system – make sure the homeowner knows how to visually inspect the flame and adjust the restrictor.

Not Enough Air

If clinkers (ashes that solidify into a clump) develop or the flame appears lazy and slow to blow the ash out of the firepot, pull the restrictor outward until the flame becomes active and the firepot holes remain clean. NOTE: If the restrictor is fully out, yet the firepot does not remain clean, the stove needs to be cleaned and checked for air leaks (see “Maintenance” section of this manual).

Too Much Air

If the flames are too active (small, flickering flames) or if burning pellets are expelled from the firepot, move the restrictor rod inwards until the flame slows down and no burning pellets are expelled. Another symptom of too much air is the heater “blowing the fire out” – a condition in which the pellets burn faster than they are fed (this is most common on low)

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1 3

Thermostat Installation

!Do not connect 120 VAC to the thermostat circuit of this heater (do not use a

household thermostat used for a wall-board or other electical heater).

A thermostat is included with this heater (part # 99300650). Follow the directions below to install.

1Attach the thermostat wire to the circuit board (see the illustration below). Route the wire through the back of the heater (away from any hot or moving components).

50

60

70

80

90

Pull the cover off the thermostat

50 60 70 80 90	Run the thermostat wires
	through the wall (cut off excess
	wire, leaving 6” of slack).

Attach the quick-connects to the two posts near the molex connector on the circuit board (orientation does not mater).

2Determine a location for the thermostat that is within range of the 20' length of thermostat wire. It should be centralized in the room and away from the heater. The wire may be routed externally on the wall or behind the wall (preferred).

3Follow the directions to the right to attach the thermostat and thermostat wires.

Expose 1/2” of wire and attach to these two posts.

Standard

Screwdriver

Attach the thermostat to the wall through these

two holes.

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